INTRO TO TECHNOPRENEUR DUK 5112

INTRODUCTION

Mini CNC Milling Machine for training kit is a machine like any other CNC milling
machine. But the clearly noticeable of this CNC machine is this CNC machine is much
smaller than other CNC milling machines that are being used at industry today. It still
has the X, Y and Z axis movement and these axes are move automatically. Because of
its small size, this CNC Milling Machine is easy to convey as teaching material in the
class. The main materials for this machine are aluminum because these materials are
much lighter than mild steel.

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INTRO TO TECHNOPRENEUR DUK 5112

2.2 MARKET RESEARCH

Before starting any project, market research is one of the important steps that
must be done. The elements of the market research explained in the sub chapter below.

2.2.1 DATA COLLECTION

Data / information gathered through:-
 Survey / observation

 Schools, college and university.

 Interview

 From the interview the result shown that the device still not widely
used.
 The devices also have many functions for using.
 Then the other information gained is the advantages and limitations
of the project.

 Reading and Research

 By the research from the references books some information about

designing and other additional component also information about
the most suitable material.

 Via web / Internet

 By the internet research, the information about the types of the

sheet metal, design about a milling machine, and some details
about machining processes.

2.2.2 ANALYZE INFORMATION

 Relevant aspects to consider when analyze information

 Estimate material cost

 Overhead cost
 Project function to customer

2.2.3 LIST OF IDEA TO SOLVE PROBLEM

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 Methods to gain idea

 Discussion
 Brainstorming

 Problem solving identification

Why : Why the product is produce?

To become cheaper and portable training kit
How : How to produce the product?
Machining which using fully mechanical concept.
Where : Where to market the product?
At technical institution
Who : Who is the target market for this product?
vocational training officer at technical institution.

PRODUCT DESIGN

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In this chapter the information about engineering design approach, integrate

design process, design criteria and the elements of design process is discussed. To
design is either to formulate a plan for the satisfaction of a specified need or to solve a
problem. If the plan in the creation of something having a physical reality, then the
product must be functional, safe, competitive, usable, manufacturability and marketable.
These are the characteristics of design:
 Design is an innovative and interactive process. It also decision making process.
 Design is a communication-intensive activity in which both words and pictures
are used and written and oral forms are employed.
 Designs are subject to problem solving constrains. A designer can only apply
methods he knows and understands.

PRODUCT UNIQUENESS

 Reduce maintenances cost.

 Small, portable and much lighter
 The spare parts are easy to find.
 Cheap compared to other CNC milling machine.

Project Budget

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7.1 METHOD OF COSTING

Method of costing also has to be seriously taken into consideration as to avoid

over budgeting. The methods include:
 List down the required component of the machine.
 List down the component that already have from recycle component.
 Estimate the total cost of recycle component.
 Estimate the total cost of purchase component.
 Get the total cost for the machine.

7.2 RAW MATERIAL COST

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The table 7.1 below describe about the raw material cost base on size, quantity,
and the price.
NO ITEMS SIZE (mm) QUANTITY PRICE/UNITS AMOUNT
(RM) (RM)
1 Aluminum Plate 110 x 100 x10 6 9.10 54.60
2 Aluminum Plate 110 x 320 x12 1 64.00 64.00
3 Solid Square 60 x 80 x 25 2 24.00 48.00
Bar
4 Solid Square 120 x 310 x 1 60.00 60.00
Bar 20
5 Solid Square 110 x 220 x 25 1 68.00 68.00
Bar
6 Solid Square 120 x 120 x 1 78.00 78.00
Bar 45
7 Solid Square 110 x 140 x 25 1 60.80 60.80
Bar
8 Solid Square 110 X14O x 1 51.60 51.60
Bar ( Nylon ) 50
9 Solid Round Bar Diameter 12 6 20.00 120.00
( Brass ) Length 240
TOTAL 605.00

Table 7.1 Raw Material Cost

7.3 STANDARD PARTS

Table 7.2 below shows the part size, quantity and price of the standard part in
this project.

NO ITEMS SIZE QUANTITY PRICE/UNITS AMOUNT

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(RM) (RM)
1 Threaded Rod Diameter 10 3 10 30
2 Linear Bush Inner 12 40.00 480.00
diameter 10
3 Bearing Inner 6 25.00 150.00
diameter 10
4 Flat Washer Diameter 18 6 0.30 1.80
5 Screw M5 36 0.60 21.60
6 Screw M8 16 0.80 12.80
7 Nut M5 12 0.30 3.60
8 Nut M8 16 0.50 8.00
9 Nut M10 9 0.70 6.30
10 Stepping Motor 42 x 42 3 1500.00 4500.00
With The Driver
11 Mabuchi Motor Diameter 37 1 100.00 100.00
TOTAL 5314.10

Table 7.2 Standard Part Cost

7.4 MACHINING TIME (FABRICATION)

Table 7.3 below shows the part machining, hour and rate price per hour in this
project.

NO MACHINING HOUR RATE TOTAL

(RM/HOUR) AMOUNT
1 CNC 96 40 3840.00
2 EDM Wirecut 12 60 720.00
3 Benchwork / Assembly 2 30 60.00
4 Design 48 40 1920.00

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TOTAL 6540.00

Table 7.3 Machining time (Fabrication)

7.5 SELLING PRICE

The cost for this project included overhead cost, production cost and the profit
estimated is RM 13705.00.

OVERHEAD COST = Electricity + Transportation

= RM 80 + RM 20 = RM 100

PRODUCTION COST = Raw material cost + Standard part cost +

Fabrication cost
+ Overhead cost
= RM 605.00 + RM 5314.10 + RM 6540.00

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TOTAL COST = RM 12459.10

PROFIT = 10% X TOTAL COST
= 10% X RM 12459.10
= RM 1245.90
SELLING PRICE = Total Cost + Profit
= RM 12459.10 + RM 1245.90
= RM 13705.00

PROJECT WORK WEEKLY MANUFACTURING

KKTMBP
REPORT TECHNOLOGY

Project Title: MINI CNC MILLING MACHINE SEM 5

NURAFIZ BIN MISKAN Date From: Week

MUHAMAD HIDAYAT BIN HASHIM 09-07-2009
AKRAM FAHMI BIN MOHD NASIR Date To:
Group Name:
KAMARUL ZAMAN BIN JASNI 09-07-2009 1

NO. PROCESS:

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1 Band saw Machine

 material : aluminum
 cut 110 x 38 x 16 for Rod Base (6 pieces)

2 Laser Cutting Machine

 material : stainless steel plate
 machine the Nut Cover part (6 pieces)

SKETCH / REMARK

PROJECT WORK WEEKLY MANUFACTURING

KKTMBP
REPORT TECHNOLOGY

Project Title: MINI CNC MILLING MACHINE SEM 5

NURAFIZ BIN MISKAN Date From: Week

MUHAMAD HIDAYAT BIN HASHIM 16-07-2009
AKRAM FAHMI BIN MOHD NASIR Date To:
Group Name:
KAMARUL ZAMAN BIN JASNI 16-07-2009 2

NO. PROCESS:

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1 Band Saw Machine

 material : mild steel
 cut the ‘L’ beam for Support part (1 pieces)

2 CNC Milling HAAS

 Kamarul Zaman does the squaring for the Rod Base part
 Nurafiz do the machining process for the Stock Pad (nylon plastic) part
 Akram does the squaring for Support part
 Hidayat does the squaring for the Upper and Lower Motor Holder

SKETCH / REMARK

PROJECT WORK WEEKLY MANUFACTURING

KKTMBP
REPORT TECHNOLOGY

Project Title: MINI CNC MILLING MACHINE SEM 5

NURAFIZ BIN MISKAN Date From: Week

MUHAMAD HIDAYAT BIN HASHIM 20-07-2009
AKRAM FAHMI BIN MOHD NASIR Date To:
Group Name:
KAMARUL ZAMAN BIN JASNI 20-07-2009 3

NO. PROCESS:

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1 CNC Milling HAAS

 Kamarul Zaman does the drilling process for the Rod Base part and
squaring process for the handle base.
 Nurafiz running the program by transferring G-code from master cam to
machine for stepper motor holder part.
 Akram does the drilling process for the support part.
 Hidayat running the program by transferring G-code from master cam to
machine for upper and lower motor holder part.

SKETCH / REMARK

KKTMBP KKTMBP PROJECT

PROJECT WORK WORK WEEKLY
WEEKLY MANUFACTURING
MANUFACTURING
REPORT REPORT TECHNOLOGY
TECHNOLOGY
Project PROJECT
Title: Project Title:
MINI WORK
CNC MILLING WEEKLY
MINI CNC MANUFACTURING
MILLING MACHINE
MACHINE SEM 5 SEM 5
KKTMBP
REPORT TECHNOLOGY

Group Group Name: NURAFIZ BIN MISKAN Date From: Week

ProjectName:
Title: NURAFIZ
MINIBIN
CNCMISKAN
MILLING MACHINE
MUHAMAD HIDAYAT BIN
Date From:
HASHIM 5 Week
SEM 24-08-2009
MUHAMAD HIDAYAT BIN HASHIM 03-08-2009
10-08-2009
17-08-2009 5
6
7
AKRAM FAHMIAKRAM
BIN MOHDFAHMI BIN MOHD Date
NASIR NASIRTo: Date To:
NURAFIZ BIN MISKAN
KAMARUL Date From:
ZAMAN BIN JASNI Week
24-08-2009 8
KAMARUL ZAMAN BIN JASNI
MUHAMAD HIDAYAT BIN HASHIM 03-08-2009
10-08-2009
17-08-2009
27-07-2009
AKRAM FAHMI BIN MOHD NASIR Date To:
Group Name:
KAMARUL ZAMAN
NO. PROCESS: BIN JASNI 27-07-2009 4
NO. PROCESS:
1 Gathering Data
NO. Gathering
Benchwork
1 PROCESS:
A week offData
because of the H1N1 virus spread at Kolej Kemahiran Tinggi
 Updating the weekly report.
 Updating
Make chamfering process
the weekly report.for handle base part.
 Continue making the FYP report.
1  Make
start the
makingdeburring
CNC Milling HAAS the FYPprocess
report for the sharp edges.
 Kamarul Zaman make a slot at the Rod Base part.
 Nurafiz does the drilling process for the Handle Base part.
 Hidayat does the drilling process for the upper and lower motor holder
part.
2 Conventional Turning
 Akram turning the handle and handle rod

SKETCH / REMARK
SKETCH / REMARK
SKETCH / REMARK
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